Production Engineer
Mars GCC
مجموع سنوات الخبرة :23 years, 9 أشهر
Responsible for daily production activities and increasing line efficiency.
Performing breakdown and preventive maintenance as per the planned schedule.
Facilitated Root cause analysis investigations in regard to Food Safety, safety & equipment failures.
Enforce GMP and manufacturing standards, keeping machines running at optimal levels. Ensure health and safety is paramount to prevent Quality and Safety incidents on the line.
Leading and participating in lean workshops for reducing non-value adding activities and rework. Participating in FMEA and SIPOC for upcoming lines.
Generate and implement KAIZEN ideas to improve line stability and capability of the process
Improve productivity through processes like Takt Time study and line balancing, waste elimination, improve bottle neck station, improve equipment utilization and manpower reduction.
Contribute to the continual improvement of the TPM system and implement improvement ideas. Utilizing lean tools such as Value Stream Mapping, SMED, POKA-YOKE for process optimization.
Responsible for on-job training to the operators and also developing multi-skilling of operators.
KEY ACHIEVEMENTS: -
Led Project of replacing the main drive of two wrapping machines to servo drives. The Project was successfully completed within the allocated time-line.
Driven two significant Projects in Lean Kaizen by bringing down the scrap cost from $15k to $8K.
Winner of “Annual Supply Star Program” in 2013, 2014 and 2016.
Reduced the factory consumables cost by 22%, through supplier development and negotiations.
Initiated and completed 26 kaizens to improve line efficiency and reliability.
Handling the Role and Responsibilities of Department Head - Injection Moulding.
Identifying areas of improvement and recommending process modifications to enhance operational efficiencies of machines/equipment and achieving higher productivity. maintenance as per the planned schedule. Ensuring proper use of available resources to bring in maximum output.
Coordination with M+C SCHIFFER, Germany for proceedings and developments on the mould shop. Installation of Engel machines from Austria and trials of new moulds from zahoransky, Braun, SNS, Etc. Responsible for conducting trials of the new materials and developing new vendors.
Validating the process by establishing documented evidence and confirming that a specific process consistently produces products meeting specification and quality characteristic.
Responsible for reducing down-time due to breakdowns and changeover of moulds.
Processing of PP, TPE, PETG, LDPE, HDPE and other plastics.
Conducting efficient changeovers and start-up troubleshooting.
Responsible for conducting trials of the new materials and developing new vendors.
Performing preventive and breakdown maintenance of hot runner moulds. Which included cleaning of the manifold and the shut-off assembly, replacing the nozzles and the nozzle heaters, replacing the seals and liners of the nozzle tips.
Maintaining mould spares at all times, ensuring that there is no production downtime due to unavailability of mould.
Responsible for reducing breakdowns and doing analysis of the moulds and machines and maintaining records of the same.
Responsible for preventive maintenance and breakdown maintenance of AISA High speed tube making machines from Switzerland, flexographic Printing machines from Arpeco, Canada and molding machines from Nessei, Japan and L & T and ferromatic from India .
Responsible for reducing downtime due to breakdown and increasing machine efficiency.
Responsible for doing the breakdown analysis and doing the preventive maintenance schedule of AISA machines considering the production plan.
Given a responsible project of shifting the first two AISA tube making machines from the Goa unit to the Baddi unit. Successfully completed the task by installation and commissioning of the machines at the Baddi unit within the allocated time.
Given additional responsibility of handling the engineering stores and raising purchase orders for engineering items considering their reorder point and the reorder level (MP2). Was successful in reducing the inventory level by 20% without any stoppages in the production machines due to lack of spare parts.
Responsible for developing local vendors for some original spares imported form the manufacturer of the machine.
Responsible for quality of production, handling manpower, loading and unloading of moulds as per the production plan.
Maintenance of cold runner moulds. Two plate/three plate, single gate/multi gate moulds.
Process setting of injection molding machines, mould and molding accessories.
Processing of ABS, HIPS, PP, PET, PS, PC, SAN and other engineering plastics.
As a shift/production supervisor, responsible for production and quality, optimizing cycle time, increasing machine utilization and reducing scrap.
Responsible for carrying out trials of new moulds and modifications, for increasing machine utilization, and for achieving stringent quality standards set by the customers.
4 yrs Diploma Course